Rotary Drum and vibratory conveyor system

ABSTRACT

A rotary drum and vibratory conveyor system including a single walled rotary drum positioned above a vibratory conveyor assembly. The rotary drum may be segmented with each segment having end flanges that are connected to an adjoining segment with bolts. A section or sections of the rotary drum have perforations covered by a dust hood that allow sand and media to fall from the drum through a funnel structure onto the conveyor assembly. The vibratory conveyor assembly includes upper and lower conveyors, where the upper conveyor collects the media falling from the drum and passes the sand to the lower conveyor. The media may be redirected back to the drum inlet to be reused.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a rotary drum and conveyor system, and more particularly, to a single walled rotary drum with perforations and a vibratory conveyor system.

2. Description of the Related Art

Devices found in the related art use a rotary drum having inner and outer shells, the inner shell consisting of a removable liner and the outer shell functioning to retain sand and media.

Such prior art having inner and outer shells are readily shown in U.S. Pat. Nos. 3,998,262, 4,674,691, 4,981,581, 5,016,827, 5,095,968, and 5,267,603 all of which are incorporated herein by reference. These patents disclose a double shelled machine that are very expensive to maintain, as their inner liner design is not easy to repair or replace, and if one section breaks in the double shelled devices, the entire liner has to be removed to repair the one section.

BRIEF SUMMARY OF THE INVENTION

Without limiting the scope of the invention, a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description below. A brief Abstract of the technical disclosure in the specification is provided as well, but only for the purposes of complying with 37 C.F.R. 1.72. The Abstract is not intended to be used for interpreting the scope of the claims. All U.S. patents and applications and all other published documents mentioned anywhere in this Application are incorporated herein by reference in their entirety.

The inventive system disclosed here uses a single walled rotary drum for reclaiming material from a casting process and includes a vibratory conveyor assembly. The design is a single walled rotary drum, as opposed to other devices found in the art. Instead of using complicated and expensive liners, the drum disclosed here uses modular sections or segments that are easy to remove and can easily be swapped for different segment configurations. A rotary drum eliminates the need for a laborer to spend an excessive number of hours repairing and cleaning a casting by hand. The disclosed rotary drum is more energy efficient by using a single wall. Since a single walled rotary drum weighs far less than the double walled drums of the prior art, less energy is required to rotate the drum. In addition, a single walled drum results in lower casting temperatures in the drum. Instead of using a complicated apparatus, the single walled rotary drum here uses modular sections, which are easy to remove, and the sections or segments may be easily swapped for different configurations, including, but not limited to perforated segments or solid walled sections. Underneath the rotary drum portion of the system is a vibratory conveyor assembly consisting of upper and lower conveyors. The vibratory conveyor assembly removes material exiting the drum through a funnel. The vibratory conveyor provides a cost efficient and a more productive apparatus to separate sand and media from castings. The invention contemplates a number of embodiments where any one, any combination of some, or a combination of all of the embodiments can be incorporated into a rotary drum system for reclaiming material, including a vibratory conveyor assembly and a method of use of the drum and conveyor system. At least one embodiment of the invention is directed to a rotary drum constructed out of a multiplicity of interlocking geometrically shaped segments consisting of different configurations, having inner and outer surfaces, the inner surface mounting a helical vane, the configurations running from a solid wall of steel to having various sized openings for removal of material, and then reclaiming the material using a vibratory conveyor. The geometric shapes of interlocking segments include, but are not limited to circles, rectangles, trapezoids, octagons, and hexagons. The rotary drum comprises two or more geometrically shaped segments connected by a connector.

The principal object of the invention is to provide a single walled rotary drum and vibratory conveyor system to separate sand and media from foundry formed castings. This and other objects will become apparent to those skilled in the art upon a review of the follow disclosures in light of the accompanying drawings.

In accordance with the invention, generally stated, a system of a single walled rotary drum constructed out of a multiplicity of interlocking geometrically shaped segments and a vibratory conveyor assembly is provided which separates surface disposed core sand from fresh castings by tumbling the castings in the presence of adhesive media. The drum is constructed out of a multiplicity of interlocking sections or segments, having an inner surface mounting a helical vane. The drum is defined by modular bolted sections, each section having a predetermined length. Each section may consist from one of a variety of different configurations, from being a solid piece of steel to having various sized openings within the wall for removal of product. The drum is defined by two or more segments, including an entrance segment wherein the surface disposed mold sand is removed from the castings by tumbling, and an exit segment through which materials are removed from the rotary drum and placed onto a vibratory conveyor assembly, the exit segment also enabling cleaned castings to exit the drum. The entrance segment defines an entrance to the drum and may include rifling for moving castings longitudinally there along. The wall of the rotary drum is constructed from a multiplicity of interlocking geometrically shaped segments having a plurality of openings, and the openings have a plurality of diameters and dimensions, through which sand removed from the castings may pass. The exit segment includes a series of openings through which the abrasive media and any residue loosened sand from the castings pass to the vibratory conveyor assembly.

At the entrance, the rotary drum includes an annular wheel which rotates with the drum. The annular wheel has a plurality of spaced paddles which receive the abrasive media particles and lift them upwardly to reintroduce them into the drum.

The geometric shape of the segments and how they are connected determines the length of the drum. In at least one embodiment, the cross-sectional shape of the segments is round. The segments may consist of a variety of different lengths.

At least one embodiment of the invention is directed to a single walled rotary drum made up of two or more geometrically shaped segments that can be placed together. Each segment has an inner and an outer surface, with the inner surface mounting a helical vane, and may consist of a variety of different configurations, from being just a solid wall of steel to having various sized openings for removal of product. A connector pulls the segments together and the connector tension pulls the segments closely together, with specially shaped locking points on the segments fitting into each other and causing the segments to become “locked.” The locking points can be similarly shaped surfaces or edges of the segments laying flush against each other or they can be highly complex locking mechanisms. As the segments lock together they form a single rotary dram.

The drum is driven at a low number of revolutions per minute by a commonly available drum drive package.

One embodiment of the invention is directed to a system of a rotary drum and one or more vibratory conveyors. Underneath the rotary drum is the one or more vibratory conveyors. The primary or upper conveyor collects the sand and media that is ejected from the rotary drum, and separates the sand from the media. The rotating drum is surrounded by a non-rotating fixed structure which funnels the extracted sand and media unto the vibratory conveyor below.

In foundry applications, the vibratory conveyor assembly is formed of metal to stand up to the continued abrasion of sand and media. A conveyor assembly is disclosed which includes a supporting frame, an article transporting bed which is orientated in spaced relation relative to the supporting frame, a plurality of resilient supports mounted to both the supporting frame and the article transporting bed and which supports the article transporting bed, and a drive which provides power to move the transporting bed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with accompanying drawing, in which:

FIG. 1 is left side isometric view of a rotary drum and vibratory conveyor system in accordance with the present invention.

FIG. 2 is a right side isometric view of the rotary drum and vibratory conveyor system shown in FIG. 1.

FIG. 3 is a top plan view of the rotary drum shown in FIGS. 1 and 2, but without a drive system or a dust hood.

FIG. 4 is a left side elevation view of the rotary drum and vibratory conveyor system shown in FIGS. 1 and 2.

FIG. 5 is a top plan view of the rotary drum and vibratory conveyor system shown in FIGS. 1 and 2.

FIG. 6 is an enlarged view of two segments of the rotary drum shown in FIGS. 1-5.

FIG. 7 is a cross section view of a portion of the rotary drum illustrating the vibratory conveyor system in more detail.

FIG. 8 is a schematic cross section view of another embodiment of the rotary drum and vibratory conveyor system.

FIG. 9 is a schematic elevation view of the rotary drum and vibratory conveyor system shown in FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention will next be illustrated with reference to the figures wherein, unless otherwise indicated, the same numbers indicate similar elements in all figures. Such figures are intended to be illustrative rather than limiting and are included herewith to facilitate the explanation of the system of the present invention.

The invention is directed to a rotary drum and vibratory conveyor system for use in separating media and foundry sand from molded castings. This description will clearly enable one skilled in the art to make and use the invention, and describes embodiments, adaptations, variations, alternatives and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.

The present system overcomes the prior art limitations by providing a unique rotary drum and vibratory conveyor system.

Referring now to FIGS. 1-5, there is shown a rotary drum and vibratory conveyor system 10 having a base fame 12 supporting a single walled, segmented drum 14 and a vibratory conveyor assembly 16. The rotary drum 14 is made up of a plurality of interlocking segments 20, 22, 24 which fit together to form the cylindrically shaped drum. A motor drive system, with a motor 30, a drive gear 32 and a drive belt 34 engage a drive ring 36 on the drum. A funnel structure 40, FIGS. 4 and 7 guides sand and media falling from the drum to a sand handling vibratory conveyor 42.

The drum moves castings, sand and media along the drum longitudinally from an inlet end 50 to an outlet end 52. As shown, located near the outlet end 52 of the drum is the drum segment 24 that has a plurality of holes or perforations to allow the sand and media to fall from the drum 14 through the fixed funnel structure 40 to the conveyor 42 to extract the sand and media. Each drum segment 20, 22, 24, as shown in FIGS. 1-4 and 6, has a laterally extending flange at each end, such as the flanges 60, 62 of the drum segment 20, the flanges 64, 66 of the drum segment 22 and flanges 68, 70 of the drum segment 24, that positively lock together so that the drum segments may be individually replaced as they wear or need repair, one section of the drum at a time. This feature of the invention decreases the cost of repair, installation and replacement and decreases the amount of time needed to repair a rotary drum.

As seen in FIG. 6, the drum segments are connected together using bolts, such as the bolt 80. Each segment of the drum may be configured from any one of a variety of different designs, from having a solid wall, as shown for the segments 20 and 24, to walls having various sized openings for removal of sand and media product, as shown for a portion of the segment 24.

Castings initially enter the rotary drum from the inlet fed by a vibratory feeder or the like. The castings move along the rotary drum because the drum includes an inner surface 82 having helical vanes 84, 86. The drum also moves sand and media with the castings along the drum.

Referring now to FIGS. 8 and 9, another embodiment of a rotary drum and vibratory conveyor system 100 is shown and includes a base frame 102, a drum 104, a conveyor assembly 106, including upper and lower conveyors 108, 110, a dust hood 112, an inlet conveyor 114, a discharge conveyor 116, a vibratory mechanisms including springs, such as the spring 120, and stabilizers, such as the stabilizer 130, and a motor 140, and a control panel 142 connected to a gear reduction motor 144. The gear reduction motor controls a drive pinion 146. The drive pinion rotates and torques a drive ring 148 around the drum. Perforated sections 150 of the rotary drum are enclosed by the dust cover 112 and the funnel structure 152 to deposit sand and media falling from the drum onto the upper media conveyor 108 and the lower sand conveyor 110.

Sand and media in the drum enter the perforated sections 150 of the drum, and based on sizes of the sand and the media material, the material will sieve through the perforated sections 150, and be contained by the dust hood 112 and the fixed funnel structure 152 dropping the extracted sand and media into the vibratory conveyor assembly below. The dust hood has an inner surface 160, an outer surface 162, and a port 164, all as seen in FIG. 8. Gravitational force causes the sand and media to fall directly through the funnel 152 and land on the vibratory conveyor assembly 106.

As shown the rotary drum 104 is mounted and supported on left and right wheels 170, 172 found on either side of the drum. Directly above the left wheel 170 is an access panel 174 into the perforated section of the drum.

Referring again to FIG. 8, the rotary drum is driven at a low number of revolutions per minute by a commonly available drum drive motor 144. The drum drive motor is amounted on the base frame 102.

The rotary action of the drum 104 gently tumbles the castings, while the media helps scrub the castings clean. The castings, media and sand are conveyed through the drum to the perforated sections where the sand is removed from the drum through small perforations 180, FIG. 9. The castings and the media continue along the remaining sections of the drum where the media is removed from the drum through large perforations 182 and is discharged onto the vibratory conveyor assembly 106, as shown in FIG. 9. The sand previously discharged falls through the upper conveyor onto the lower vibratory conveyor 110.

The section of the drum located closest to the inlet preferably possesses more perforations so that the sand which is separated from the castings may fall into the fixed funnel structure 152.

The vibratory conveyor assembly 106 directs the sand and media in an opposite longitude direction from the movement found in the rotary drum. The vibratory conveyor assembly returns the sand and media either to a location for further processing or to the inlet of the drum.

The vibratory conveyor assembly 106 is comprised of two conveyors, as shown, an upper conveyor 108 and a lower conveyor 110. The upper and the lower vibratory conveyors lie underneath the funnel structure 152 which guides the extracted sand and media onto the vibratory conveyors below. The upper and lower vibratory conveyors extend underneath the drum 104 in a longitude direction. The upper and lower conveyors are of an adjustable, predetermined length traveling parallel to the drum.

The lower conveyor 110 lies underneath the upper conveyor 108. The upper vibratory conveyor is placed so the upper conveyor collects sand and media material under an initial select section of the drum. The upper vibratory conveyor 108 is constructed with additional perforations for separation of sand or the like from the media. The lower vibratory conveyor collects sand, which is displaced from the upper vibratory conveyor, and conveys the material beyond the length of the upper vibratory conveyor to another conveyor 188, FIG. 9. The upper vibratory conveyor 108 conveys the media back to the drum inlet where the upper conveyor deposits the media into a paddle wheel 190 attached to the rotary drum. The paddles of the wheel elevate the media distribution back into the rotary drum. The embodiment shown in FIGS. 1-7 also include a dust hood 112 and support wheels 171, 173, 193, 194, as well as longitudinal thrust wheels 200, 202. The embodiment of FIGS. 1-7, also includes conveyor springs 120 and stabilizers 130, and a motor 140. 

1.-13. (canceled)
 14. A rotary drum and vibratory conveyor system comprising: a base frame; a single walled rotary drum mounted to the base frame, the rotary drum having an intake end portion and a discharge end portion, the wall of the rotary drum having a section with a plurality of perforations; a dust hood mounted to the base frame and position over the section of the rotary drum having the plurality of perforations; a funnel structure mounted adjacent to and extending below the section of the rotary drum having the plurality of perforations, and an upper and lower conveyer assembly mounted to the base frame and positioned adjacent to and below the funnel structure to receive material falling through the perforations from within the rotary drum, wherein the material is guided by the funnel structure.
 15. The drum and conveyor system of claim 14 wherein: the drum is formed of a plurality of individual segments, each segment having a longitudinal length and first and second end portions and each end portion of each segment.
 17. The drum and conveyor system of claim 14 wherein: the rotary drum includes a section having perforations of different sizes.
 18. The drum and conveyor system of claim 14 including: a material return structure mounted to the intake end portion of the rotary drum wherein the material return structure is fed by the upper and lower conveyor assembly.
 19. The drum and conveyor system of claim 14 wherein: the funnel structure includes slanted walls.
 20. The drum and conveyor system of claim 19 wherein: the slanted walls of the funnel structure extend from the dust hood to a location adjacent the upper and lower conveyor assembly.
 21. The drum and conveyor system of claim 14 wherein: an upper conveyor of the upper and lower conveyor assembly includes structure to pass smaller material and capture larger material falling from the rotary drum. 22 The drum and conveyor system of claim 21 wherein: a lower conveyor of the upper and lower conveyor assembly includes structure to capture the smaller material.
 23. The drum and conveyor system of claim 14 wherein: the drum is formed of a plurality of individual segments, each segment having a longitudinal length and first and second end portions, and each end portion of each segment having an axially directed flange for facilitating connection of one drum segment to another drum segment; each flange includes holes to enable the integral drum segment to be connected to another drum segment with bolts; and the rotary drum includes a section having perforations of different sizes.
 24. The drum and conveyor system of claim 23 including: the funnel structure includes slanted walls.
 25. The drum and conveyor system of claim 24 wherein: an upper conveyor of the upper and lower conveyor assembly includes structure to pass smaller material and capture larger material falling from the rotary drum.
 26. The drum and conveyor system of claim 14 wherein: the drum is formed of a plurality of individual segments, each segment having a longitudinal length and first and second end portions, and each end portion of each segment having an integral axially directed flange for facilitating connection of one drum segment to another drum segment; each flange enables the integral drum segment to be connected to other drum segments with bolts; and the rotary drum includes a section having perforations of different sizes.
 27. The drum and conveyor system of claim 26 wherein: the funnel structure includes slanted walls; and the slanted walls of the funnel structure extend from the dust hood to a location adjacent the upper and lower conveyor assembly.
 28. The drum and conveyor system of claim 27 wherein: an upper conveyor of the upper and lower conveyor assembly includes structure to pass smaller material and capture larger material falling from the rotary drum.
 29. The drum and conveyor system of claim 28 wherein: a lower conveyor of the upper and lower conveyor assembly includes structure to capture the smaller material.
 30. The drum and conveyor system of claim 14 including: a drive system mounted to the base frame to enable rotation of the drum; alignment structure mounted to the base frame to restrict movement of the rotary drum in a longitudinal direction; and wherein the funnel structure includes slanted walls; the slanted walls of the funnel structure extend from the dust hood to a location adjacent the upper and lower conveyor assembly; an upper conveyor of the upper and lower conveyor assembly passes smaller material and captures larger material falling from the rotary drum; and a lower conveyor of the upper and lower conveyor assembly captures the smaller material.
 31. The drum and conveyor system of claim 30 wherein: the drum is formed of a plurality of individual segments, each segment having a longitudinal length and first and second end portions, and each end portion of each segment has an integral axially directed flange for facilitating connection of one drum segment to another drum segment; and each flange enables the integral drum segment to be connected to other dram segments with bolts.
 32. A method for sorting material using a rotary drum and conveyor system comprising the steps of: introducing material to be sorted into a single walled rotary drum, the drum having a section with perforations through the wall of the drum; rotating the drum; passing the material in the drum through the perforations and through a funnel; and depositing the material on an upper and lower conveyor assembly, wherein larger material is deposited on an upper conveyor of the upper and lower conveyor assembly and smaller material falls through the upper conveyor to land on a lower conveyor of the upper and lower conveyor assembly.
 33. A method for assembling a rotary drum and conveyor system comprising the steps of: mounting a rotary drum to a base frame, the rotary drum having a single wall wherein a portion of the wall is perforated; mounting a funnel structure to the base frame; and mounting a vibratory upper and lower conveyor assembly to the base frame beneath the funnel structure to enable material within the drum to pass through the perforated wall of the drum, the material thereafter being guided by the funnel structure before falling onto the upper and lower conveyor assembly. 